WQ0000484_Permit Renewal_20190731

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State of North Carolina
Division of Water Resources
Water Qu.1. Regional Operations Section
Environmental Staff Report
Quality
To: ❑ NPDES Unit Z Non -Discharge Unit
Attn: Tessa Monday
From: Jim Barber
Fayetteville Regional Office
I. GENERAL AND SITE VISIT INFORMATION
1. Was a site visit conducted? ® Yes or ❑ No
a. Date of site visit: 19 June and 23 July 2019
Application No.:. WQ0000484
Facility name:- Mountaire Farms Inc. — Lumber Bridge
b. Site visit conducted by:. Jim Barber and Tony Honeycutt
c. Inspection report attached? ❑.Yes or ® No
d. Person contacted: Robert Jackson and their contact information: 9( 10) 359 - 5275 ext.
riackson(@mountaire.com
e. Driving directions: From the intersection of NC Hwv 20 and NC.Hwv 71 in Lumber Bridge, take Hwy 71
west towards Red- Springs and drive approx.. 1.70 miles The Mountaire Farms plant site is on the right.
2. Discharge Point(s): N/A
Latitude: Longitude:
Latitude: Longitude:
3. Receiving stream or affected surface waters: Big Marsh Swamp
Classification: C - Sw
River Basin and Sub -Basin No.: Lumber River/LBR53/14-22=2
Describe receiving stream features and pertinent downstream uses: Predominantly agriculture and forest
management. Sanderson Farms spray irrigation fields are approx. 6 miles downstream, St. Pauls
II. PROPOSED FACILITIES: NEW APPLICATIONS
1. Facility Classification: (Please attach completed rating sheet to be attached to issued permit)
Proposed flow:
Current permitted flow:
2. Are the new treatment facilities adequate for the type of waste and disposal system? ❑ Yes or ❑ No
If no, explain:
3. Are site conditions (soils, depth to water table, etc) consistent with the submitted reports? ❑ Yes ❑ No ❑ N/A
If no, please explain:
FORM: WQROSSR 04-14 Page 1 of 6

4. Do the plans and site map represent the actual site (property lines, wells, etc.)? ❑ Yes ❑ No ❑ N/A
If no, please explain:
5. Is the proposed residuals management plan adequate? ❑ Yes ❑ No ❑ N/A
If no, please explain:
6. Are the proposed application rates.(e.g., hydraulic, nutrient) acceptable? ❑ Yes ❑ No ❑ N/A
If no, please explain:
7. Are there any setback conflicts for;proposed treatment; storage. and disposal sites? ❑ Yes or ❑ No
If yes, attach a map showing conflict areas.
8. Is the proposed or existing groundwater monitoring program adequate? ❑ Yes ❑ No ❑ N/A
If no, explain and recommend any changes to the groundwater monitoring program:
9. For residuals; will seasonal or other restrictions be required? [IYes ❑ No ElN/A
If yes, attach list of sites with restrictions (Certification B)
Describe the residuals handling and utilization scheme:
10. Possible toxic impacts to surface waters:
11. Pretreatment Program (POTWs only):
III. EXISTING FACILITIES: MODIFICATION AND RENEWAL APPLICATIONS
1. Are there appropriately certified Operators in Charge (ORCs) for the facility? ® Yes ,Z No ❑ N/A
ORC: Robert Jackson Certificate #: SI-14876 Backup ORC: Derrick Mallety Certificate #: SI-993134 .
ORC: Derrick Mallety Certificate #: W W-4/1004828 Backup ORC: Robert Jackson CertificateWaW�2/r2+12r7,
2. Are the design, maintenance and operation of the treatment facilities adequate for the type of waste and disposal
system? ® Yes,or ❑ No
If no, please explain:
Description of existing facilities: As written in the current spray irrigation permit W00000484. Facility
treatment works being upgrade to include biological treatment and sludge removal verses current DAF
treatment and aeration kn storage basin Domestic now will still go thru the BioWheel TM treatment unit
adiacent to the storage lagoon.
Proposed flow: 2.55 MGD
Current permitted flow: 2.55 MGD
Explain anything observed during the site visit that needs to be addressed by the permit; or that may be important
for the permit writer to know (i.e.,-equipment condition, function, maintenance, a change in .facility ownership,
etc.)
3. Are the site conditions (e.g., soils, topography, depth to water table, etc) maintained appropriately and adequately
assimilating the waste? ® Yes or ❑ No
If no, please explain:
4. Has the site changed in any way that may affect the permit (e.g., drainage added, new wells inside the compliance
boundary, new development, etc.)? ❑ Yes or ®.No
If yes, please explain:
5. Is the residuals management plan adequate? ® Yes or ❑ No
If no, please explain: All solids currently removed by DAF units are removed from the site and processed
system will be dewatered by the current 2400 GPM secondary DAF unit and will be land applied in South
Carolina by Denali (merger of Denali and TRS) Backup management of the biological residuals will be
thru a contract with McGill Environmental.
FORM: WQROSSR 04-14 Page 2 of 6

6. Are the existing application rates (e.g., hydraulic, nutrient) still acceptable? ® Yes or ❑ No
If no, please explain:
7. Is the existing groundwater monitoring program adequate? ❑ Yes ® No ❑ N/A
If no, explain and recommend any changes to the groundwater monitoring program: Kent White is working
with Duncklee & Dunham, groundwater consultants for Mountaire — Lumber Bridge, on the updated
groundwater monitoring system and is reviewing GW-59s for the new wells in conjunction with the older,
existing wells Kent has had two meetings with D & D and Mountaire technical staff concerning nitrate
exceedances at the review boundary and in a couple of locations the compliance :boundary. Once a few
additional samples are received for the new overall monitoring system, an NORR most likely will be
drafted (possible NOV) to inform Mountaire of the need to remediate the nitrate violations.
8. Are there any setback conflicts for existing treatment, storage and disposal sites? ❑ Yes or ® No
If yes, attach a map showing conflict areas.
9. Is the description of the facilities as written in the existing permit correct? ® Yes or ❑ No
If no, please explain:
16. Were monitoring wells properly constructed and located?, ® Yes ❑ No ❑ N/A
If no, please explain: See comment #7 New groundwater monitoring wells have been installed and sampled.
Pa
FORM: WQROSSk 04-14 Page 3 of 6

11. Are the monitoring well coordinates correct in BIMS? ® Yes ❑ No ❑ N/A
If no lease complete the following (expand table if necessary):
Monitoring Well
Latitude
Longitude
.
O I fl
_ O I If
. O 1 It
_ O I it
O 1 II
O I If
o 1 n
_ o r rr
O 1 1/
_ O I II
12. Has a review of all self -monitoring data been conducted (e.g., DMR, NDMR, NDAR, GW)? .® Yes or ❑ No
Please summarize any findings resulting from this review: Reviewed monthly by Tony Honeycutt and Kent
White.
- Provide input to help the -permit writer evaluate any requests for reduced monitoring, if applicable.
13. Are there any permit changes needed in order to address ongoing BIMS violations? ❑ Yes or No
If yes, please explain:
14. Check all that apply:
® No compliance issues
❑ Notice(s) of violation
® Current enforcement action(s) ❑ Currently under JOC
® Currently under SOC ❑ Currently under moratorium
Please explain and attach any documents that may help clarify answer/comments-(i.e., NOV, NOD, etc.).
Mountaire Farms is not under an NOV/Enforcement/SOC issued by the Division of Water Resources at
this time.
The Division of Air Quality has Mountaire under a compliance action/schedule and currently under an
SOC with Mountaire Farms with a compliance date of October 2019. At this time Mountaire intends to
have all wastewater treatment plant upgrades complete by mid to late August and hopefully will have final
If the facility has had compliance problems during the pen -nit cycle, please explain the status. Has the RO been
working with the Permittee? Is a solution underway or in place?
Have all compliance dates/conditions in the existing permit been satisfied? ❑ Yes ❑ No ® N/A
If no, please explain:
15. Are there any issues related to compliance/enforcement that should be resolved before issuing this permit?
❑ Yes ®No❑N/A
If yes, please explain:
16. Possible toxic impacts to surface waters: N/A
17. Pretreatment Program (POTWs only): N/A
FORM: WQROSSR 04-14 Page 4 of 6

i
IV. REGIONAL OFFICE RECOMMENDATIONS f
1. Do you foresee any problems with issuance/renewal of this permit? ❑ Yes or ❑ No
If yes, please explain:
4
2. List any items that you would like the NPDES Unit or Non -Discharge Unit Central Office to obtain through an
additional information request:
Item Reason
3. List specific permit conditions recommended to be removed from the permit when issued:
Condition Reason
4. List specific special conditions or compliance schedules recommended to be included in the permit when issued:
Condition Reason
5. Recommendation: ❑ Hold, pending receipt and review of additional information. by regional office
❑ Hold, pending review of draft permit by regional office
❑ Issue upon receipt of needed additional information
Issue
❑ Deny (Pee state reasons: }
6. Signature of report preparer: ��A",
Signature of regional supervisor: 1M cf?Q /t— FofZ Ime.4,77 ALGW
Date:
FORM: WQROSSR 04-14 Page 5 of 6

V. ADDITIONAL REGIONAL STAFF REVIEW ITEMS
Two site visits were made to Mountaire Farms Lumber Bridge (Mountaire) during the construction of wastewater
treatment plant upgrades.
The first site visit on 19 June 2019 was the result of the partial engineering certification for the new 1100 GPM
primary DAF unit The approved design called for an 800 GPM DAF unit but an alternative larger capacity DAF was
installed With this new 1100 GPM DAF unit Mountaire has 3500 GPM of primary DAF capacity and 2400 GPM
secondary DAF capacity to support the MBBR system upgrades. The Fayetteville Regional Office does not have any
concerns or issues with installation of a high capacity DAF unit than the one specified in the approved design. With
Mountaire's current plant slaughter capacity and wastewater flow each primary DAF unit is receiving approximately
400 and 500 GPM depending on number of chickens processed per day.
The second site visit on 23 Jiily'2019 was the result of the partial engineering certification for the installation of the
aeration system blowers/manifolds and diffusers for each MBBR tank Electrical panels blower motors. and 90% of
the piping were complete on 23 July 2019 The remaining 10% of the piping for the MBBR system was to be
completed the last week of July or first week of August Electricians are scheduled to be on -site the first and second
weeks of August to start up the blower system Once the remaining wiping is installed and MBBR tanks filled with
potable water to check for leaks; the blower and aeration system will be tested Once all initial testing is complete
with potable water, any issues that arise or repairs needed' the tanks will be emptied to allow workers access to areas
that need repairs or modification.
Once the final engineer's certification is provided for the entire protect and approval to operate granted by the
_Division Mountaire will introduce wastewater and the filter/treatment media (see example provided with this staff
report) and will fill each MBBR tank proximately 1/3 to 1/2 full There are approximately 450 super -sacks of
filter/treatment media to be installed (4'x4'x4'= 64 ft3 x 450 = 28,800 ft3) with approximately 14 400 cubic feet per
MBBR tank. Once the filter inedia start sinking in the MBBR tank due to biofilm then Mountaire will increase the
volume of wastewater in each tank.
FORM: WQROSSR 04-14 Page 6 of 6

Zee% . J�sJrS
State of North .Carolina.
Department of Environmental Quality
c Division of Water Resources
WATER QUALITY REGIONAL OPERATIONS SECTION
ivision.of Water. Resources NON -DISCHARGE APPLICATION REVIEW REQUEST FORM .
i
June 17,, 2019. DQlVV.
To: IE',R®=WQROS T"Trent Allen / Mir' *Brantl-e';D 2019
From: Tessa Monday, Water Quality Permitting Section - Non -Discharge Branch
Permit Number: WQ0000484
Applicant: Mountaire Farms, Inc.
Owner Type: Organization-
Facility Name: Mountaire Farms - Lumber Bridge WWTF
Signature Authority: Jim Zuniga
V61RU0
Permit Type: Wastewater Irrigation
Project Type: Minor Modification
Owner in BIMS? Yes
Facility in BIMS? Yes
Title: Engineering & Maintenance Manager
Address:. PO Box 339, Lumber Bridge,.NC.28357 County
/QO GCS o.v
Fee Category: n Ae Fee Amount: $0 = Renewal
Comments/"O.ther Information: FRO -copy of application��i`s on;LaserfiOi
Attached, you will find all. information submitted in support of the above -referenced application. for your. review,
comment, and/or action. Within 45 calendar days, please take the following actions: .
® Return this form completed. Return a completed staff report.
0 Attach an Attachment B for, Certification.. ❑ . Issue an Attachment B Certification.
When you receive this request form, please write your name and dates in the spaces below, make a copy of this sheet; and
return it to the appropriate Central Office Water Quality Permitting Section contact person listed above.
RO-WQROSReviewer:
Date:
FORM:

�'b
ROY COOPER
Governor
MICHAEL S. PEGAN
Secretary
LINDA CULPEPPER
Director
NORTH CAROLINA
Environmental Quality `
June 17, 2019
JIM ZUNIGA —ENGINEERING & MAINTENANCE MANAGER
MOUNTAIRE FARMS, INC.
PO Box 339
LUMBER BRIDGE, NORTH CAROLINA 28357
Subject: Acknowledgement of
Application No. WQ0000484
Mountaire Farms - Lumber Bridge
WWTF
Wastewater Irrigation System
Durham County
Dear Mr. Zuniga:
The Water Quality Permitting Section acknowledges receipt of your permit application and
supporting documentation received on June 14, 2019. Your application package has been assigned the
number listed above, and the primary reviewer is Tessa Monday.
Central and Regional Office staff will perform a detailed review of the provided application, and
may contact you with a request for additional information. To ensure maximum efficiency in processing
permit applications, the Division of Water Resources requests your assistance in providing a timely and
complete response to any additional information requests.
Please note that processing standard review permit applications may take as long as 60 to 90 days
after receipt of a complete application. If you have any questions, please contact
Tessa Monday at [phone] or [e-mail].
Sincerely,
Nathaniel D. Thornburg, Supervisor
Division of Water Resources
cc: a yettev-iile_RegionatOffice,_W. _ate�Quafity Regional 0_perations Section
Permit File WQ0000484
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�� North Carolina Department of Environmental Quality I Division of Water Resources
512 North Salisbury Street 1 1617 Mail Service Center I Raleigh, North Carolina 27699-1617
NO IA CAMUNA
oqa ntofE w War\ /'� 919.707.9000